Pallet nibbler method

ABSTRACT

A method of manufacturing a configured cut-out in a sheet of material by arranging a pair of dies to support a sheet of material therebetween, pushing a punch shaft through one die, then through the sheet of material and then through the other die, then retracting the punch shaft to effectuate initiation of a nibbling operation to produce a cut-out in the sheet of material to correspond to a cut-out in a template, which template is traced by a pilot finger during common motion of the template and the sheet of material.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention relates to a method of utilizing a high speed punchingand nibbling apparatus for cutting out portions of flat sheet material.

(2) Prior Art

Metal pallets have been recently devised so as to provide means forarticulating several layers of shoe or fabric parts with respect to oneanother, wherein they may be stitched together by automatic sewingmachines. The pallets are made from several layers of template-likesheet metal, hinged together at a common edge, as shown in U.S. Pat. No.3,988,993. The sheet metal has cut-outs therein, which define the pathto be followed by stitching needles. The cut-outs for these pallets maybe done by hand, which is time consuming, and difficult to do accuratelyor they may be done expensively by numerical controlled millingmachines. Those machines are not always at a shoe or garmentmanufacturing facility, because of their expense, size and complexity.This thus requires a long lead time for changing a pattern on a palletif a shoe or garment manufacturer wishes to do so. Other methods andmachines may be utilized to manufacture the cut-outs in the sheet metal,by drilling or punching a hole in the material, then utilizing anibbling machine or saw to cut out any particular pattern.

U.S. Pat. No. 3,760,676 shows a complex rotary drive punch machine fornibbling cut-outs in sheet material, comprising a clutch mechanism,thrust ball arrangements and other devices presenting a complicatedapparatus.

U.S. Pat. No. 4,168,644 shows a punching and nibbling device whichrequires stopping of the operation to change tools before going aheadwith the nibbling sequence. Similar relationships are shown in U.S. Pat.Nos. 4,241,631 and 3,988,829.

These machines represented by these patents do not permit a simplearrangement for punching and nibbling a cut-out in one or a series ofpieces of sheet material.

It is an object of the present invention, to provide a combinationpunching and nibbling machine which will overcome the disadvantages ofthe prior art.

It is an object of the present invention, to provide a method ofpunching and nibbing a cut-out in sheet material, utilizing a commontool unrealized in the prior art.

It is a further object of this invention, to provide a fast, repeatableand accurate method for cutting out sections in sheet material, such assheet metal, laminates, plastic or the like.

BRIEF SUMMARY OF THE INVENTION

The present invention comprises a novel method utilizable for producingtemplates for aiding in the subsequent manufacture of multi-layer goodssuch as shoes or garments. The method uses a machine having a framewhich supports an X-Y base on which a master template may be disposed.The master template on the X-Y base may be moved orthogonally withregard to a fixed pilot arm. The fixed pilot arm extends from a portionof the frame, in spaced relation to a nibbling arrangement. The pilotarm has a finger on its distal end which is matable with the mastertemplate mounted on the X-Y base. A blank sheet of material to be madeinto an article of manufacture such as a pallet component may be lockedinto adjoining disposition on the X-Y base, adjacent the mastertemplate. The blank sheet of material may have an arrangement ofalignment holes therein, through which a plurality of tapered pins mayfit, properly locking the blank sheet into the X-Y base, providingaccurate alignment between it and the master template as well as thenibbling arrangement.

The nibbling arrangement through which the blank sheet of material ismovably disposed, comprises a reciprocably upwardly and downwardlymovable upper die, a lower supporting die and a punch shaft displaceablevertically through each die. The punch shaft has a lower end which isattached through eccentric bearing means, to a motor which provides oneof driving means for the punch shaft. The motor is mounted on amotivated sub-frame for guiding the punch shaft through the lowermovable die.

A displacement means, such as a pneumatic piston and cylinderarrangement is secured to the frame and is attached at the lower portionof the sub-frame to vertically displace the sub-frame, the punch shaft,and the motor thereon.

The distal (upper) end of the punch shaft is adapted to have punch meansthereat, so as to permit the punch shaft to make its own initialpenetration of any blank sheet of material disposed within the nibblerarrangement. The punch shaft has a nibbling section adjacent (verticallybelow) the punch means, comprising a narrowed portion tapering from theouter periphery, inwardly and upwardly, which taper extends from theouter surface of the shaft to a narrow portion which defines an uppershoulder, having a definite circumferential edge which comprises thenibbling means on the punch shaft.

The punch shaft may be caused to punch an initial opening in a blanksheet due to the punch shaft being pushable therethrough by thedisplacement means arranged between the frame of the machine, and thesub-frame carrying the punch shaft and motor as well as by the rotationof the motor to add to the impetus thus comprising a combineddisplacement means. Upon creation of the initial opening, the motor iscaused to continue rotating, effectuating a reciprocating stroke in thepunch shaft, raising and subsequently lowering the nibbling means from alevel above the surface of the sheet material to a level below the lowerside of the sheet material, nibbling away cresent shaped chips of sheetmaterial with each reciprocating stroke once the sub-frame, motor andpunch shaft have been pushed to their highest position by the combineddisplacement means.

The punch shaft follows a path determined by the master template whichtemplate is movable (together with the sheet of material on the X-Ybase) with respect to the finger on the fixed pilot arm. The X-Y basemay be moved manually on the frame of the machine, by a machineoperator, who traces the contour to be cut-out, by moving the mastertemplate so as to make the finger on the pivot arm follow the contoursin the master template.

The upper die is disposed on the lower end of an adjustable shaft whichis journalled in a sleeve member. The adjustable shaft is pivotablyconnected to a first link, which first link is also connected to aswingable arm fixedly attached to a rotatable shaft, journalled at thetop of the machine. When the rotatable shaft is rotated, it causes theswingable arm to pull on the first link, moving the adjustable shaft(and upper die) out of the way for cleaning and or replacement thereof.

Thus, a new pallet component duplicating the configured cut-out(s) ofthe master template may be manufactured a lot faster, and lessexpensively by a novel manufacturing method and apparatus, permittingrapid change of styles of shoes or garments being stitched together by ashoe or garment manufacturer. These new pallet components may beduplicated right in the manufacturer's facilities because of thesimplicity, minimum size and minimum cost of the punch-nibbling systemwhich produces these new articles of manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects and advantages of the present invention will become moreapparent when viewed in conjunction with the following drawings, inwhich:

FIG. 1 is a perspective view of a punch-nibbling machine constructedaccording to the principles of the present invention, showing a newarticle of commerce manufactured therewith;

FIG. 2 is a side elevational view partially in section, of thepunch-nibbling mechanism, with the article produced thereby; and

FIG. 3 is a side elevational view, partially in section showing thedetails of a portion of the punch-nibbling mechanism in a further step.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings in detail, and particularly to FIG. 1,there is shown a novel template punch-nibble machine 10 comprising aframe 12 on which an X-Y base 14 is slidably disposed. The X-Y base 14may lockingly carry a master template 16 and a blank sheet of material18 which is to be cut-out in a pattern of cut-outs 20 duplicative ofthat in the master template 16 and thereby produced as a new article ofcommerce.

A fixed pivot arm 24 extends from an upper "C" shaped portion 26 of theframe 12, over the central area of the master template 16, which ismovable therebeneath. The pilot arm 24 has a rotatable finger 30vertically journalled at the distal end thereof, the finger 30 beingmatable with the periphery of any cut-out(s) 20 in the master template16.

The blank sheet of material 18 may have an arrangement of alignmentholes 32 therein, registertable with socket means therebeneath, on theX-Y base 14, a tapered pin 34 being matably registerable through thealignment holes 32 and their respective sockets, not shown, in the X-Ybase, to properly align the sheet of material 18 with the template 16,and a nibbling mechanism 40.

The nibbling mechanism 40 is partially shown in FIG. 1 wherein the sheetof material 18 is movably disposed thereat and is also shown in FIGS. 2and 3. The nibbling mechanism 40 comprises a reciprocably upwardly anddownwardly movable upper die 48 secured to the lower end of an axiallydisplaceable shaft 50. The mid portion of the displaceable shaft 50 isjournalled in a sleeve 52 attached to the distal end of the upper "C"shaped portion 26 of the frame 12. The upper end of the displaceableshaft 50 is attached to a pivotable link 54, at the top of the shaft,which itself is pivotably connected to a swingable arm 56, which arm 56is secured to a horizontally disposed shaft 60, journalled in a pair ofsupports 62 arranged on the upper distal end of the upper "C" shapedportion 26 of the frame 12.

The nibbling mechanism 40 also comprises a lower portion, shown in FIGS.2 and 3 having a punch empowering means 70 which may be a pressurizablepiston or the like, attached to the frame 12. A piston rod 72 extendsupwardly from the empowering means 70, and is connected to the lower endof a first lower shaft 74 which is journalled through an extension 75 ofthe frame 12 and is attached to a movable sub-frame 76. An electricmotor 80 is secured to the sub-frame 76, and has an eccentric outputshaft 82 to which a connecting rod 84 is attached. A punch shaft 86 issecured, at its lower end, to the connecting rod 84, the punch shaft 86being journalled in a sleeve assembly 90 which sleeve assembly 90 issecured to a portion of the frame 12. The sleeve assembly 90 includes athreaded nut 92 which holds a lower die 94 to a threaded coupling 96inside a housing 100.

The punch shaft 86 has an upper end 101 which is reciprocably disposablethrough an opening 102 in the lower die 94 and through an opening 104 inthe upper die 48. The lower and upper dies 94 and 48 each have orifii106 on their sides to permit metal chips to escape during the nibblingoperation.

The upper end 101 of the punch shaft 86 has a concave uppermost surface107 with sharp peripheral edges, as shown in FIGS. 2 and 3. This permitsa punching or cutting action therewith as the shaft 86 is initiallypushed through the article of commerce being formed.

Inwardly along the shaft 86 from the concave surface 107 of the upperend 101 of shaft 86, there is a shoulder section 108 providing a steppedreduction in diameter of the shaft 86. This shoulder section 108 tapersinwardly to a thinner diameter of the shaft 86 a longitudinal distancetherealong at least equal to the distance the eccentric bearing 84oscillates the shaft 86.

The top surface of the lower die 94 is in supportive contact with thelower surface of the sheet of material 18 being punched and nibbled,which is sheet metal, in this embodiment.

In operation of the machine 10, the sheet of material 18 to bepunched/nibbled is loaded onto the X-Y base 14. The distance between thefinger 30 and the punch shaft 86 is the same as the distance between thealignment holes 32 on the surface securely supporting the mastertemplate 16 and the alignment holes 32 on the article of sheet material18 being transformed into a pallet or new article of commerce. It is tobe noted that the holes 32 could easily be notches at correspondingedges or the like.

A knob 110 is disposed on the distal end of an arm 112 secured to theend of the horizontal shaft 60 to enable a machine operator to cause thelink 54 and swingable arm 56 to straighten out and effectuate thedisplacement of the displaceable shaft 50 downwardly, to cause the lowersurface of the upper die 48 to be disposed against the article 18 beingmanufactured, holding it securely, against the top surface of the lowerdie 94 while still permitting it to be moved transversely therebetween.

Proper actuation of the punch empowering means 70 effectuateslongitudinal upward displacement of the piston rod 72, pushing upwardlythe first lower shaft 74, the sub-frame 76 holding the motor 80, and thepunch shaft 86, from a position shown in FIG. 2 to the position of thosecomponents as shown in FIG. 3. Simultanously with the actuation of thepunch empowering means 70, the motor 80 may be energized by propermeans, not shown, to effectuate the cyclical reciprocation of the punchshaft 86 as it is advanced toward and through the article topunched/nibbled. This combined pushing by the empowering means 70together with the drive by the motor 80 permits a smaller empoweringmeans 70 to be utilized than would otherwise be required to punchthrough a piece of sheet material 18 typically metal, from which thearticle of commerce is being manufactured.

Upon punching through the sheet of material 18, as shown in FIG. 3, themotor 80 still effectuates reciprocating motion in the punch shaft 86,while the empowering means 70 is held stationary at its fulldisplacement position. The shoulder section 108 of the upper end 101 ofthe punch shaft 86 just clears the upper surface of the sheet ofmaterial 18, and the sheet of material 18 may be moved, together withthe entire X-Y base 14, preferably by hand, with the rotatable finger 30following the contour of the cut-out(s) 20 in the template 16. As thesharp, hardened shoulder section 108 is moved in its cycle downwardly,nibbles a "C" shaped piece of material from the sheet of material 18 asit is being moved between the dies 48 and 94.

The finger 30 is preferably of circular cross-section, of a diameterequal to the diameter of the punch shaft 86 at the smaller diameteradjacent the shoulder 108. The finger 30 may be allowed to rotate as itis caused to trace the contours of the cut-out(s) 20. The finger 30 maybe of larger (or smaller) diameter than the nibbling portion of thepunch shaft 86, and if so, the corresponding portion(s) cut-out from thearticle of manufacture 18 would then be smaller (or larger) than thecut-out(s) 20 of the master template 16 by a dimension equal to thedifference of their respective radii.

Thus there has been shown a novel manufacturing method utilizable in theshaping of an article of manufacture, wherein a single tool is used toboth punch and nibble a flat sheet of material, the tool being driven bya combination of means permitting the minimization of the punch drivingmeans, the overall cost of the equipment, and the time necessary tooperate the machine. The article of manufacture described herein, may bemade from a sheet of metal, plastic, a laminate or the like.

Though the invention is described in particular terms it is intendedthat the appended claims be interpreted as exemplary only, and not in alimiting sense.

I claim:
 1. A method for manufacturing a configured cut-out in a sheetof material, comprising the steps of:arranging a first die to support asheet of material thereon; bringing a second die into oppositerelationship with said first die, so as to be able to secure a sheet ofmaterial therebetween; pushing a punch shaft through said first die;punching a hole through said sheet of material with said punch shaft andinto said second die; and lowering said punch shaft while still keepingit through said hole and while moving the sheet of material to initiatenibbling of the sheet of material by said punch shaft.
 2. A method formanufacturing a configured cut-out in a sheet of material, as recited inclaim 1, including:rotating a motive means to provide reciprocatingmotion to said punch shaft.
 3. A method for manufacturing a configuredcut-out in a sheet of material, as recited in claim 2, including:movinga template with respect to a pilot finger so as to trace a pre-arrangedcut-out configured therein; moving the sheet of material to be cut-outin a pattern corresponding to the movement of the template.
 4. A methodfor manufacturing a configured cut-out in a sheet of material, asrecited in claim 2, including:raising said motive means with said punchshaft to effectuate said punching operation.
 5. A method ofmanufacturing a configured cut-out in a sheet of material, as recited inclaim 4, including;holding said motive means in its raised positionduring the nibbling operation.
 6. A method for manufacturing aconfigured cut-out in a sheet of material, as recited in claim 5,including:lowering said motive means to effectuate lowering of saidpunch shaft from said first and second dies.